Method for manufacturing improved fatigue life structures, and structures made via the method

ABSTRACT

A method for cold working metal structures. A compound indenter is used to produce deformation in a workpiece, to provide a selected beneficial residual stress profile, to provide improved fatigue life structures with minimal manufacturing steps. A compound indenter deforms a workpiece, resulting in dimples therein. A relatively uniform beneficial residual stress profile is provided at the surface and at the midplane of apertures in a workpiece, so as to improve overall fatigue life. A compound indenter tool having a first, elongate indenter with a shaped indenter surface portion, and a second shaped indenter surrounding the first indenter and forming an annular shoulder recessed from the surface portion of the first indenter, is used. Optionally, a foot having a bottom portion is used to confiningly surround an indenter during application of deforming force to the surface of a workpiece, to prevent deformation of adjacent workpiece surface.

RELATED PATENT APPLICATIONS

This patent application is a divisional of copending allowed U.S.application Ser. No. 09/782,880 filed Feb. 9, 2001, entitled “METHOD ANDAPPARATUS FOR MANUFACTURING STRUCTURES WITH IMPROVED FATIGUE LIFE”,issued as U.S. Pat. No. 6,742,376 on Jun. 1, 2004, which claimedpriority under 35 U.S.C. §119(e) from U.S. Provisional Application Ser.No.: 60/181,290, filed on Feb. 9, 2000, the disclosure of each of whichis incorporated herein by their entirety by this reference.

COPYRIGHT RIGHTS IN THE DRAWING

A portion of the disclosure of this patent document contains materialthat is subject to copyright protection. The inventor has no objectionto the facsimile reproduction by anyone of the patent document or thepatent disclosure, as it appears in the Patent and Trademark Officepatent file or records, but otherwise reserves all copyright rightswhatsoever.

TECHNICAL FIELD

This invention is related to novel methods for the manufacture offatigue prone structures, and their components, and particularly metalparts having apertures therein, including, but not limited to, aperturesutilized (a) for accommodating connecting elements, such as rivets,bolts, pins, screws or other fasteners, or (b) for accommodating tubing,cable, wires, rods, or other actuators, (c) for weight reductionpurposes. Additionally it can be applied to guns, pressure vessels orother structures carrying pressurized fluid loads. Individualcomponents, sub-structures, and overall finished structures can bemanufactured utilizing the method and apparatus disclosed herein inorder to achieve improved resistance to metal fatigue, and thus to haveimproved structural integrity.

BACKGROUND

Metal fatigue is a problem common to just about any component orstructure that experiences cyclic stresses or repetitive loading. Suchproblems are especially important in the metal structures utilized invarious components of transportation systems as they experience avarying amount of repetitive loads during normal operation. Structuresor components that are prone to fatigue damage include, but are notlimited to, commercial and private transport aircraft, general aviation,military aircraft, helicopters, jet engines, turbines, passenger cars,trucks, off-road equipment, construction vehicles, heavy constructionequipment, boats, ships, trains, rolling stock, railroad track,stationary and moving bridges, medical implants, pressurized pipes andvessels, guns, cannons and the like.

Metal fatigue can generally be defined as the progressive damage,usually evidenced in the form of cracks, that occurs to structures as aresult of cyclic or repetitive loading. The lower surface of an aircraftwing is a classical example of the type of loading that producesfatigue. The wing is subjected to various cyclic stresses resulting fromgust, maneuvering, taxi and take-off loads, etc., which over the servicelife of the aircraft can produce fatigue damage.

Fatigue damage is generally observed, at time of initiation, in the formof growth of small cracks from areas of highly concentrated stress.Typical stress concentrators include holes, fillet radii, abrupt changesin section, notches, and the like. Fatigue damage can often be hidden tothe untrained because it generally occurs under loads that do notgenerally cause yielding or deformation of the structure. In fact,failure usually occurs under loads typically experienced in theoperation of the structure. Undetected, a fatigue crack can grow untilit reaches a critical and catastrophic size or length. At the criticallength, the unstable crack races through the metal, causing suddenfailure of the component. Catastrophic failure of the entire structure,such as a wing or fuselage, can occur when other members of thestructure can not carry the additional load from the failed member.

Even stationary objects such as railroad track, pressurized vessels andartillery equipment may fail in fatigue because of cyclic stresses.Cyclic loads caused by repeated loading due to rail car wheels runningover an unsupported span of railroad track are the cause of many trackfailures. In fact, some of the earliest examples of fatigue failureswere in the railroad and bridge building industry. Sudden pressurevessel failures can also be caused by repeated pressurization cyclesacting on initially small cracks. It is not surprising that U.S.governmental studies report that fatigue damage is a significanteconomic factor in the U.S. economy.

While many methods have been developed and utilized for the manufactureof structures having improved fatigue life at fasteners, it wouldnevertheless still be desirable to reduce the amount of handlinginvolved in producing such structures. That is because such adevelopment would facilitate reduced manufacturing costs of enhancedfatigue life structures, thus reducing the cost of end productsutilizing such structures, and/or enabling more widespread use ofimproved fatigue life components in industrial applications.

SUMMARY

An novel tool for working a structure to improve the fatigue strength ata selected location in the structure has been developed. Specifically,the tooling involves the provision of a compound indenter, of either asolid one-piece integral construction, or of adjustable multi-partconstruction, which includes a primary indenter with a contacting endfor engagement with and deformation of a pre-selected portion of a firstsurface of the structure being worked, to impart a desirable residualstress profile in said body of the structure. The primary indenter has afirst shaped surface with a preselected profile designed to impart thedesired stress profile, and a sloping peripheral wall to facilitateremoval of the indenter from the workpiece. The compound indenter,whether of the solid, integral one-piece design or of the adjustabledesign, also includes a secondary indenter having a second shapedsurface having a preselected surface profile. The primary indenter andthe secondary indenter are configured for engagement with the structurebeing worked. For the creation of the usual round holes in a workpiece(such as for rivets or other fasteners), the primary indenter and thesecondary indenter are arranged concentrically on the working end of thecompound indenter. In this manner, the secondary indenter is preferablysituated, longitudinally, so as to form an annular shoulder having aninner ring edge around the primary indenter. In some cases, a verynarrow, annular secondary indenter is followed by, radially outwardly, asloping blend radius, and then a tertiary indenter surface. Next,another blend radius is located radially outward of the tertiaryindenter surface. Ideally, a concave foot portion is located radiallyoutward from the final indenter (as described, the tertiary indenter),and finally, a flat foot portion extends radially outward in the sameplane as the top surface of the work piece being indented. When acircular hole is being formed, and a circular indenter is beingutilized, the foot is annular in shape and confiningly structurallysurrounds the outermost (normally secondary or tertiary indenter) toprotect said first surface of the structure being worked against surfaceupset when the compound indenter acts on the first surface of thestructure.

Importantly, in thick stacks of workpieces, a second compound indenter,of similar construction to that just described for the first compoundindenter, can be utilized in the same fashion against a second side ofthe lowermost workpiece. In this fashion, desirable residual compressivestresses can be created at a preselected location throughout the body ofeach workpiece in the thick stack.

Use of the novel tooling described herein enables the practice of animproved method for the manufacture of a joint that includes overlappingat least first and second structural members. The method involvescontacting a preselected portion of the first structural member with afirst compound indenter at a pressure greater than the yield point ofthe composition of the structural member to deform a portion of thefirst structural member in a manner so as to impart a pre-selectedresidual stress at a location at or near a selected location for a firstfastener aperture through the first structural member. Preferably, theindenter shape and the amount of indentation are selected in order toimpart a residual compressive force that is substantially uniform alongthe entire length through the body of the first structural members alongsidewall portions of a first fastener aperture. A second structuralmember is provided which has therein, or at least a location formanufacture therein, a second fastener aperture defined by a secondsidewall portion. The second structural member can be either unworkedwith respect to improved fatigue resistance, or separately worked, orsimultaneously worked by utilizing opposing compound indenters. Then,the apertures for holes in the first and second structural members aremachined by reaming, to define, by their respective sidewall portions,the first fastener aperture in the first structural member, and thesecond fastener aperture in the second structural member. To finish thejoint, a fastener is inserted through the common hole created byalignment of the first and second fastener apertures, and then thefastener is secured.

This improved method can also be advantageously utilized by employingdynamic compound indenter to impinge the surface of a metal workpiece,preferably in a direction normal to the surface. The action of thedynamic compound indenter causes waves of elastic and plastic stress todevelop and propagate through the metal. Where appropriate, a platen orstationary indenter can be utilized to support a workpiece. In anyevent, properly applied and focused plastic stress waves impart a largezone of residual stress, readying the impact area for fabrication of afastener hole. A drill, reamer, or other cutting device is positionedconcentric to the impact zone from a circular compound indenter. Whenthe hole is machined, a small rebound of the stresses surrounding thehole occurs. Such rebound manifests itself as shrinking of themanufactured hole. For this reason, the cutting tools used in thismethod may require the use of a feature, i.e., back-taper, that takesinto account the inward metal movement in a hole. Otherwise, possiblebinding of the cutting tool might lead to reduced cutting tool life orto pore hole finish. Significantly, however, the desirable inwardcompressive stress are present at the edge of the manufactured hole tocounteract potentially damaging stresses focused at the aperture edge.

Importantly, the tooling provided herein is uniquely adapted to highspeed automation of the manufacture of holes and the joining of parts,particularly with rivets and other fasteners. Consequently, thesimplified embodiments depicted herein should be considered exemplary,and not restrictive, as those of ordinary skill in the art and to whomthis disclosure is directed will, having reviewed this disclosure, beable to directly adapt the tooling and the method disclosed to larger,more complex structures for manufacture of many important structures,such as aircraft components.

Objects, Advantages and Novel Features

The herein described manufacturing process for producing enhancedfatigue life parts and structures can be advantageously applied toapertures for fasteners, to large holes, to non-round cutouts of aworkpiece, to other structural configurations with thick material or tostackups of thinner material that make up a thick stack of materials.Treating a workpiece structure for fatigue life improvement, prior tofabricating the aperture itself, has significant technical and costadvantages. The method is simple, is easily applied to robotic andautomated manufacturing methods, and is otherwise superior to thosemanufacturing methods heretofore used or proposed.

From the foregoing, it will be apparent to the reader that one importantand primary object of the present invention resides in the use of anovel method for treating a workpiece to reduce fatigue stressdegradation of the part while in service. The method reducesmanufacturing costs, and both simplifies and improves quality control inthe manufacture of parts with enhanced fatigue life.

Other important but more specific objects of the invention reside in theprovision of an improved manufacturing process and of improvedmanufactured products with enhanced service life when subject to fatiguestress, as described herein, which:

-   -   Eliminates the requirement for mandrels;    -   Eliminates the requirement for split sleeves;    -   Eliminates the need for disposable split sleeves;    -   Minimizes or eliminates the need for lubrication and subsequent        clean-up during manufacture of apertures for fasteners and other        objects:    -   Allows for cold working of multi-component structures that have        a bonding compound or wet sealant between adjacent metallic        components;    -   Enables the production of a wide range of aperture diameters, in        which a wide range of diameters are employed, in a single        manufacturing step, rather than with different mandrel for each        small increment in aperture size;    -   Allows the magnitude and depth of the residual stress to be        carefully controlled, by control of the amount of force or        energy input into the part or structure the indenters, or by        control of dimple depth or other measure of displacement or        indentation;    -   Enables process control to be established using feedback in the        manufacturing system, enhancing quality assurance;    -   Eliminates shear tears in the workpiece, as commonly encountered        in mandrel manufacturing methods;    -   Significantly reduces or effectively eliminates surface marring        and upset associated with mandrel methods, thus significantly        increasing fatigue life;    -   Is readily adaptable to automated manufacturing equipment, since        manufacturing cycle times are roughly equivalent to, or less        than, cycle times for automated riveting operations;    -   Enables aperture creation after fatigue treatment, by a single        reaming operation, rather than with two reaming operations as        has been commonly practiced heretofore;    -   Is low enough in cost that it can be effectively applied to        other critical structures, such as fuselage structures, which        are typically not treated because of cost;    -   Is effective at treating deep stackups of material, including        multiple layers;    -   Is effective at treating thick structure where the comparative        thickness of the stack elements differ greatly, i.e., one thick        and one thin;    -   Is effective at treating a wide range of alloys.

Other important objects, features and additional advantages of myinvention will become apparent to the reader from the forgoing and fromthe appended claims and the ensuing detailed description, as thediscussion below proceeds in conjunction with examination of theaccompanying drawing.

BRIEF DESCRIPTION OF THE DRAWING

The invention may be more readily understood and appreciated by athorough review of the enclosed drawing, which includes the followingfigures:

FIG. 1 shows a side view of a solid, integral, one-piece, compoundindenter that has, in a radially outward direction from the centerline,a small, distal, primary indenter, a lead taper adjacent thereto, asloping peripheral wall radially outward, a second blend radius, asecondary indenter, and a third blend radius to reach the outsidediameter of the compound indenter.

FIG. 2 illustrates the use of two compound indenters, each of the typejust illustrated in FIG. 1, now showing the use of opposing compoundindenters against top and bottom members of a thick stack of material.

FIG. 3 illustrates a compound indenter having a primary indenter with aworking length which is adjustable with respect to the face level of asecondary indenter.

FIG. 4 illustrates the use of a compound indenter as just illustrated inFIG. 3 above, but now also including a foot or stop confininglysurrounding the secondary indenter, where the stop minimizes surfaceupset in the structural workpiece.

FIG. 5 illustrates the use of first and second compound indenters, eachof the type shown in FIG. 5, with an adjustable first primary indenteradjusted to a different penetration depth than a second primaryindenter, and with the first and second compound indenters acting onopposing sides of a thick workpiece.

FIG. 6 illustrates the zero hoop stress profiles resulting from theaction of a single, simple, prior art indenter of 0.210 inch (5.33 mm)diameter, with a suitable end profile acting against the work surface ofa workpiece, before reaming to form the desired hole in the workpiece.

FIG. 7 illustrates the zero hoop stress profiles resulting from theaction of a single, simple, prior art indenter of 0.210 inch (5.33 mm)diameter, with a suitable end profile acting against the work surface ofa workpiece, after reaming to form the desired hole in the workpiece.

FIG. 8 illustrates the zero hoop stress profiles resulting from theaction of a single, simple, prior art indenter of 0.300 inch (7.62 mm)diameter, with a suitable end profile acting against the work surface ofa workpiece, before reaming to form the desired hole in the workpiece.

FIG. 9 illustrates the zero hoop stress profiles resulting from theaction of a single, simple, prior art indenter of 0.300 inch (7.62 mm)diameter, with a suitable end profile acting against the work surface ofa workpiece, after reaming to form the desired hole in the workpiece.

FIG. 10 illustrates the stress profiles resulting from (1) the action ofa single, simple prior art indenter of 0.210 inch (5.33 mm) diameter,with a suitable end profile acting against the work surface of aworkpiece, after reaming to form the desired hole in the workpiece, (2)the action of a single, simple prior art indenter of 0.300 inch (7.62mm) diameter, with a suitable end profile that provides an optimumpressure profile against the work surface of a workpiece, after reamingto form the desired hole in the workpiece, and (3) a compound indenterof the type taught herein, having a primary indenter diameter of 0.210inch (5.33 mm) and a secondary indenter diameter of 0.300 inch (7.62 mm)diameter, with the primary and secondary indenters each having asuitable end profile that provides an optimum pressure profile againstthe work surface of a workpiece, with the zero hoop stress profile shownafter reaming to form the desired hole in the workpiece.

FIG. 11 shows the use of a pair of adjustable compound indenters astaught herein to indent the obverse side of a workpiece that is placedon a platen, so that the adjustable compound indenters can be actuateddownward against the workpiece to provide suitable indentations thereinso as to provide a desired residual compressive stress pattern aftermanufacture of desired holes through the workpiece.

FIG. 12 shows the use of a pair of adjustable compound indenters astaught herein to indent (a) the obverse side of a workpiece, and (b) thereverse side of a workpiece, so that the adjustable compound indenterscan be actuated (1) downward against a workpiece, and (2) upward againsta workpiece, to provide suitable indentations therein so as to provide adesired residual compressive stress pattern after manufacture of desiredholes through the workpiece.

FIG. 13 is a perspective view of an embodiment of the adjustablecompound indenter, showing the adjustable primary indenter, the nose capwith secondary indenter attached to the primary indenter housing, theindenter block adapter from which the primary indenter housing issupported, a bottom plate, top plate, and side plate for housing theadjustment actuator and 90 degree speed reducer for connection to astepper or servo motor (not shown) or other suitable drive foradjustment of the length of the primary indenter, and a threaded adapterfor attachment of the adjustable compound indenter to an indenter rampress drive.

FIG. 14 is a vertical cross sectional view of the adjustable compoundindenter first illustrated in FIG. 13, additionally showing certaininternal components, including a drive pin and 90 degree speed reducerfor connection to a stepper motor (not shown) or other suitable drivefor turning the primary indenter in its threads to achieve verticaladjustment of the length of the primary indenter, as well as showing thenose cap with integral secondary indenter which is attached to theprimary indenter housing, and the indenter block adapter from which theprimary indenter housing is supported, and a bottom plate, top plate,and side plate for housing the adjustment actuator and 90 degree speedreducer, and a threaded adapter for attachment of the adjustablecompound indenter to an indenter ram press drive, as well asillustrating the impact of such an adjustable compound indenter againsta workpiece therebelow.

FIG. 15 is an exploded perspective view of the adjustable compoundindenter just illustrated in FIGS. 13 and 14, now additionally showingcertain internal components, threads for attachment of the threadedadapter to the top plate, threads for threaded attachment of the primaryindenter housing to the bottom plate, threads for threaded attachment ofthe nose cap with integral secondary indenter to the primary indenterhousing, and external threads on the primary actuator for threadedengagement with internal threads (see FIG. 14) in the primary indenterhousing, vertical adjustment of the primary indenter with respect to thesecondary indenter in this adjustable compound indenter.

FIG. 16 is a top view taken looking down at the inside of the nose capwith integral secondary indenter, as if through line 16-16 in FIG. 17.

FIG. 17 is a partially broken away side view of a nose cap with integralsecondary indenter.

FIG. 18 is a close-up partial cross-sectional view of the nose cap justillustrated in FIG. 17, now showing details of the nose cap, whichdetails appear, radially outward, as an integral secondary indenter, afirst blended radius, an integral tertiary indenter, a second blendedradius, a concave foot portion, and a flat foot portion.

FIG. 19 is a cross-sectional view of the adjustable primary indenter asillustrated in FIGS. 14 and 15, now showing external threads used fordriving the adjustable primary indenter up and down in the primaryindenter housing.

FIG. 20 illustrates the use of opposing, integral, one-piece compoundindenters on a thick stack, to create desirable residual stresses inboth the first side of an upper workpiece and in the second side of alower workpiece, so that desirable compressive stress is createdthroughout the thick stack.

FIG. 21 shows the step of drilling or reaming a hole in one or moreworkpieces, here showing a first workpiece where a dimple has beenformed by action of a compound indenter as taught herein, and a secondworkpiece wherein the step of indenting the metal to improve fatiguelife as taught herein has not been utilized.

FIG. 22 illustrates the use of a flush rivet with a shank portion tojoin a first workpiece having a chamfered hole edge therein toaccommodate the flush rivet head, and a second workpiece having astraight or transverse hole edgewall therethrough for accommodating theshank of the rivet.

FIG. 23 illustrates the use of rivet having a round head to join a firstworkpiece having a straight or transverse hole edgewall therethrough,and a second workpiece also having a straight or transverse holeedgewall therethrough.

FIG. 24 illustrates the step of drilling or reaming a blind hole or deadend passage in a thick workpiece, wherein the workpiece has been treatedby that has been formed by action of a compound indenter as taughtherein.

In the various figures, like structures will be noted with likereference numerals or letters, without further mention thereof.

DESCRIPTION

A novel indenter has been developed for cold working treatment ofmetallic structures, and most advantageously, relatively thickstructures, or “deep stacks” of metallic structure. This indenter isthus advantageously utilized in the manufacture of various fatigue lifeenhanced structures. For the purposes of this disclosure, a thickstructure or deep stack is considered to be a material having an overallthickness T that is about two times the diameter D of the hole thatpasses through the material, or greater (i.e., T≧2D)

Importantly, the indenter shape disclosed herein can be used onautomated manufacturing equipment, including fastener installationdevices, and other devices that span a continuum of strain ranges. Theseinclude process applications in the creep range (quasi-static) fortreating strain sensitive materials, and high speed (dynamic impact) fortreating material with low strain rate sensitivity or those benefitingfrom the higher rate.

As is illustrated in FIG. 1, a unique indenter 18 is provided with anend shape that is characterized by compound shape on the working end.Specifically, a first indenter 20 of overall diameter D1, also calledthe small or primary indenter, is located at the leading edge of asecond indenter 22 of overall diameter D2, also called the large orsecondary indenter, both of which are formed, if integrally, on anindenter shaft 24. Normally, both the first indenter 20 and the secondindenter 22 are smaller than the selected fastener hole diameter. Theprimary indenter 20 allows for great indentation depth, resulting indesirable residual stresses at the interior of a deep stack, forexample, a deep stack 30 of elements 32 and 34, as seen in FIG. 2.

The secondary indenter 22 imparts a high level of residual stress at ornear the surface 36 of element 32, and, if used, at or near surface 38of element 34. The length L1 of the primary indenter 20 is governed bythe amount of indentation desired which in turn is governed by theoverall thickness (and specific material) of stack 30. The indenter 18is designed such that the secondary indenter 22 engages the stacksurface(s) 36 or 38 at a point where the action of the primary indenter20 begins to impart residual tensile stress at the surface 36 or 38.When the secondary indenter 22 makes contact with the surface 36 or 28of the workpiece 32 or 24, it begins to reverse the tensile stressdeveloped by the action of the primary indenter 20 by impartingcompressive stresses. In comparison, should be noted that a prior artsingle feature indenter, such as a flat bottom punch, a tapered punch,or a spherical nose punch, instead imparts a deleterious residualtensile stress at the surface, and adjacent to the hole, when used totreat a deep stack of structural material. However, as illustrated usingthe compound indenter design disclosed herein, the primary 20 andsecondary 22 indenter diameters work together to impart advantageousresidual compressive stress, preferably substantially uniformly throughthe entire thickness T_(s) of the deep stack 30. It should be understoodthat a plurality of indenter “steps” may be used depending on the stackthickness, i.e., there may be more than two. Thus, a compound indenter18 should be understood to include N steps, where N is a positiveinteger of 2 or greater.

The working face edge of the primary indenter may feature a chamfer, orsmall lead in taper or blend radius 40 to give it both a measure ofsharpness for ease of penetration and edge relief for resisting wear.The primary indenter 20 may also feature a slight taper portion 42,preferably having an angle alpha (α) of about 3° more or less, toimprove radial flow of the metal being impacted, and to facilitateremoval of the indenter 18 from a workpiece after processing. This isimportant because it might be expected that a straight shanked primaryindenter would tend to bind in any resultant dimple in a workpiece,making removal of such an indenter from a workpiece difficult afterprocessing.

The primary indenter 20 transitions (working right to left in FIG. 1) tothe secondary indenter 22 diameter D2 through the aforementioned blendradius 40 and then the taper 42, and thence into a blend radius 44, andsubsequently into secondary indenter working face 22. The working faceof secondary indenter 22 is followed by an external blend radius 46.

The deep stack indenter illustrated in FIG. 1 is shown ready for theprocessing of a single side of a work piece or of a stack of workpieces,such as stack 32 shown in FIG. 2. However, in FIG. 2, an additionalelement is introduced, in that a typical two-sided treatment of a twoelement stack 30 is shown. An indenter 24 as described in the embodimentset forth above may be advantageously provided in a fixed geometry, inthe sense that the length L1 of the primary indenter 20 is machined intothe indenter 18, i.e., it is an integral, one-piece, solid indenter.

Another embodiment for a desirable indenter is improved indenter 48,seen in FIG. 3. The indenter 48 preferably includes a hollow secondaryindenter 52 of outside diameter D52 surrounding a solid primary indenter54 of outside diameter D54. As illustrated, the primary and secondaryindenter can be considered both cylindrical, however, certainapplications (non-circular cutouts, for example) lend themselves tobeing worked by non-cylindrical or odd shaped compound indenters.Importantly, the working length L54 of the primary indenter can beadjusted, depending on the desired depth of material treatment, thestack thickness T_(s), and on the composition of material 58. In thisway the primary 54 and secondary 52 indenters can be positionedindependently. If provided in cylindrical fashion, the composite shapeof indenter 48 is similar, overall, to the solid-piece, deep stackindenter 18 described above. Moreover, it should be noted that use ofmultiple indenters (for example a two-indenter design using a primaryand secondary indenter) may provide as advantageous results as shownherein, if such multiple indentations are provided as separate,sequential tooling operations (in the example noted, with the primaryindenter tool operation preceding a secondary indenter tool operation).

Turning now to FIG. 4, a further variation of my indenter design isprovided by deep-stack indenter 60. Indenter 60 uses yet another hollowdevice (preferably, but not necessarily, in concentric cylindricalfashion) for a foot or stop 62 of outside dimension D62 that facilitatesthe manufacture of differing dimple depths in material 68. Such featuresmay be advantageously employed in the case of processing of unbalanceddeep stacks as shown in FIG. 5. In this instance, “balance” refers tothe relative thickness T1 of first stack material element 70 andcompared to the thickness T2 of the second stack material element 72. Asan example, a perfectly balanced stack would have two members 70 and 72of the same thickness and material. In such a situation, the proportionof the stack elements is 50:50, and thus the dimple depth would beequal. For unbalanced stacks, as in the 30:70 for example illustrated inFIG. 5, it may be necessary to independently control the dimple depthDD_(DIM1) of the dimple in first material 70 and the dimple depthDD_(DIM2) of the dimple in the second material 72, i.e, vary the dimpledepth in opposing sides. When using cylindrical indenters, a largerdiameter hollow cylindrical member 60 provides a stop or “foot” fortransferring load without indentation in surface 76 of first material 70or in surface 78 of second material 72. The foot 60 also providesresistance to surface upset in the surfaces 76 and 78. Use of thisunique tool, and this method of processing materials, allows completefreedom and independence in the selection of desired heights in primary,secondary, tertiary or more indenter portions N, and thus allows thedepth of treatment in opposing materials in a stack to be dissimilar.Additionally, it should be noted that in some circumstances, it may beadvantageous to provide, in an integral, one-piece combination, either(a) (1) the primary indenter, (2) the secondary indenter feature and (3)the foot, or (b) (1) the secondary indenter and (2) the foot.

In FIG. 5, it should be noted that treatment in an unbalanced stack 73allows for less indentation, i.e., small dimple depth DD_(DIM2) in thethinner material 72 of thickness T2. The lower primary indenter 54′ andsecondary indenter 52′ penetration is thus desirably smaller, which isimportant since a high amount of penetration of a thin structuralelement could cause undesired deformation. Conversely, the uppermaterial 70 requires greater penetration because of its greaterthickness T1. Because greater load is required to make a deeperpenetration than a light penetration, the foot or stop 60 isadvantageous in carrying the larger load acting on the upper element 70.Without the foot 60, the indenters 52 and 54 might achieve equilibriumat undesirable dimple depths DD_(DIM1). and or DD_(DIM2). The crosssectional contact area of the foot 60 is desirably large enough so thatat any anticipated processing load, no surface yielding on surface 76would occur as a result of its contact of the bottom 80 of foot 60 withthe surface 76 of material 70. Moreover, the foot is an important toolin automated manufacturing, where it also serves to secure a workpieceat a desired working location while the indenter acts on the workpiece.

It is a significant improvement in the art that the novel compoundindenter shapes disclosed herein provide a unique and importantadvantage for treating thick sections or deep stack-ups of material. Oneexample of data which illustrates the efficacy of the indenter designsshown herein, and of the methods of employing such indenters inimproving fatigue life of materials, can be seen by comparison of FIG.10 (which illustrates hoop stress profiles in materials worked accordingto the present invention) with the data in FIGS. 6 through FIG. 9 (whichillustrate materials worked with a single shaped end indenter). The dataillustrated in FIGS. 6 through 10 was developed by using a one-inchthick piece of 2000 series aluminum alloy as the workpiece. However, thedata apply equally to two one-half inch pieces of 2024-T3 aluminum thatare stacked on top of each other, where the back surface is theinterface between the two pieces of aluminum. First, the stress profilesresulting from the actions of individual, single shaped end indenters,both before and after machining a hole in the structure, are shown inFIGS. 6 through FIG. 9. Then, in FIG. 10, the stress profile resultsfrom the action of a compound indenter of the type taught herein,wherein the number of indenter portions N=2 was utilized. The datagenerated in FIG. 10 results from cold working a material using acompound indenter with a primary indenter 20 diameter of 0.210 inches(5.33 mm) and a secondary indenter 22 diameter of 0.300 inches (7.62mm), to provide sufficient cold working for a an adequate residualstress profile in the manufacture of a {fraction (5/16)}-inch (0.3125inch) (7.94 mm) diameter fastener hole.

Note that in FIGS. 6 through 9, the stress profiles result from only theaction of a single indenter with a suitable end profile acting on theworkpiece. Each of FIGS. 6 through 9 show only two primary regions,namely (a) the compressive stress region, and (b) and the tensile stressregion. The dividing line between the compressive stress region and thetensile stress region is designated as “the zero stress profile” lineand denoted as line “Z”. It is that line “Z” which is indicated in eachof FIGS. 6 through 9, for a series of dimple depths “dd”. Since thebenefit of cold working is derived from the size and shape of thecompressively stressed region surrounding the hole, an examination ofthe dividing line between compressive stress and tensile stress greatlysimplifies the comparison between the figures. Since the finite elementanalysis results which are presented in these FIGS. 6 through 10 aresymmetrical from top to bottom, only one-half of the material stackthickness is shown in the FIGS. 6 through 10. What is referred to in thevarious figures as the “back surface” is really the mid-plane of anentire one-inch stack, or the interface of two one half-inch pieces. The“work surface” is the side that is acted on by the indenter, to create adimple in the surface of the workpiece. The x-axis shows the radialdistance from the center of a desired {fraction (5/16)}-inch (7.94 mm)hole which is to be, or has been, manufactured (depending on whether theapplicable figure shows the stress profile before or after reaming). Aline at the left of each FIGS. 6 through 10 is designated as the “holeradius”, and the relationship of this location to the “zero stressprofile” line shows the nature of the stresses as they appear at thehole wall, i.e., the radius of the hole.

Further details seen in the various figures should be noted as follows:

FIG. 6 shows the extent of the compressive stress caused by an indenterdiameter of 0.210 inches (5.33 mm). For purposes of this example, thedimple depths “dd” imparted into the workpiece are 0.095 inch (2.41 mm),0.114 inches (2.90 mm), and 0.133 inches (3.38 mm), as shown by thevarious lines and depicted by separate legend in the figure. In thisFIG. 6, the stresses plotted for comparison are those present afterindentation of the workpiece, but before the hole is machined byreaming.

FIG. 7 shows the extent of the compressive stress caused in a workpieceby an indenter diameter of 0.210 inches (5.33 mm). Dimple depths in theworkpiece are 0.095 inch (2.41 mm), 0.114 inches (2.90 mm), and 0.133inches (3.38 mm), as shown by the various lines and depicted by separatelegend in the figure. The stresses plotted for comparison are thosepresent after (a) indentation, and (b), the hole has been machined byreaming. Note the extent of the compressive zone at the back surface,shown at the bottom of FIG. 7. It is larger, i.e, extends to through alarger radius from the center of the hole, than provided by a larger,0.300 inch (7.62 mm) diameter indenter, as can be seen by comparisonwith FIG. 9. Also note that tension forms at the work surface for alldimple depths “dd”. The presence of a tension area at the work surfaceis an undesirable condition which may be experienced when utilizing asingle diameter indenter to act on thick materials or deep stackworkpieces. Thus, this result shows why improved stress profiledevelopment when performing manufacturing operations on thick materials,i.e., deep stack workpieces, would be desirable. Such an improvedindenter tool, and an optimized method of utilizing such a tool toprovide an improved residual stress profile when processing a deepstack, is taught herein.

FIG. 8 illustrates the extent of the compressive stress caused by asingle indenter having a diameter of 0.300 inches (7.62 mm) acting on aworkpiece to produce a dimple of preselected depth. Stress profiles areindicated for dimple depths “dd” of 0.014 inch (0.36 mm), 0.034 inches(0.86 mm), and 0.053 inches (1.35 mm), as indicated by the various linepatterns depicted by separate legend, as set forth in the illustration.Note that in this FIG. 8, the stress profile illustrated is afterindentation of the workpiece, but before the hole is machined.

Next, FIG. 9 shows the extent of the compressive stress caused by anindenter of 0.300 inches (7.62 mm) diameter acting on a workpiece toproduce a preselected dimple depth “dd”. The illustrated dimple depths“dd” are 0.014 inch (0.36 mm), 0.034 inches (0.86 mm), and 0.053 inches(1.35 mm), as indicated by the various line patterns depicted byseparate legend, as set forth in the illustration. In this FIG. 9, thestress profile shown is (a) after indentation of the workpiece to form adimple, and (b) after the hole is machined. In particular, note theradial extent of the compressive zone at the work surface; utilizing thelarger diameter indenter. The compressive zone is much larger than thatimparted by utilization of the 0.210 inch (5.33 mm) indenter earlierillustrated. Importantly, desirable compressive stress is created at alldimple depths “dd”. Also, note the reduced compressive stress at theback surface when compared to that generated by the 0.210 diameter (5.33mm) indenter. This is an undesirable condition which results from theaction of the prior art indenters on deep stacks.

In order to create an optimized stress profile, we have developed acompound indenter tool, which can be utilized in obtaining an optimizedresidual stress profile in a thick workpiece or deep stack of material.The stress profile generated by action on a workpiece of our compoundindenter, having a primary indenter 20 (designated “dprim” in thefigure)diameter of 0.210 inches (5.33 mm), and secondary indenter 22(designated “dsec” in the figure) diameter of 0.300 inches (7.62 mm), isshown in FIG. 10. The elements of FIG.10 have been developed and arenoted like the data set forth in FIGS. 6 through 9 above. Importantly,the action of the compound indenter incorporates the best effects of asingle diameter indenter, without producing the undesirable effects ofsurface tension in a workpiece. As a result of using our new indentershape, a large zone of compressive stress extends through the full depthof a thick workpiece material or deep stack components. FIG. 10 showsthree lines, depicting (1) use of a simple, single indenter of 0.210inches (5.33 mm) diameter to produce a dimple depth of 0.114 inches(2.90 mm) in a workpiece, (2) a simple, single indenter of 0.300 inches(7.62 mm) in diameter to produce a dimple depth of 0.014 inches (0.36mm) in a workpiece, and (3) a compound indenter, with a primary indentershape of 0.210 inches (5.33 mm) diameter, and a secondary indenter shapeof 0.300 inches (7.62 mm) in diameter, to produce an overall dimpledepth dd of 0.100 inches (2.54 mm) in a workpiece. The extent of thecompressive stress generated by the compound indenter is greater at allareas of the workpiece when compared to either of the single diameterindenters when acting on a workpiece alone. As clearly illustrated inthis FIG. 10, the use of a compound indenter for thick workpieces anddeep stacks of materials is clearly an important advance in the art ofmanufacturing structures with improved fatigue life.

A close review of the information depicted in FIGS. 9 and 10 reveals oneaspect of the improvement provided by the present invention. In FIG. 9,the zero hoop stress line Z₁₀₀ represents a maximal extent of residualstress which can be provided using a prior art single indenter ofdiameter 0.300 inches (7.62 mm). This line has vastly different residualstress performance at the work surface 102 as compared to the backsurface 104. More precisely, the distance from the hole wall 106 of thecompressive stress along the work surface 102 as compared to thedistance of the compressive stress along the back surface 104 results ina uniformity ratio of 39.7% for this workpiece and indenter combination.In contrast, on an identical workpiece (1.00 inch (25.4 mm) thick2024-T3 aluminum plate), by using the compound indenter as taughtherein, the zero hoop stress line Z₁₁₀ shown in FIG. 10 shows that auniformity ratio of 53.9% was achieved. This represents an improvementof 36% in the uniformity ratio resulting from cold working of theworkpiece by use of or novel compound indenter.

We have found that use of dynamic indenters, while not absolutelynecessary, can be employed in carrying out the process set forth herein.In conjunction with such efforts, it is sometimes advantageous to use anoptimized profiled indenter with an uniform pressure profile, having asurface shape of the primary indenter of any compound indenter to bedefined by the equation:$p_{z} = {\frac{4\left( {1 - v^{2}} \right)P_{m}a}{E}{\int{\begin{bmatrix}{1 - {{\underset{\_}{r}}^{2}\sin^{2}\theta}} \\a^{2}\end{bmatrix}^{1/2}{\mathbb{d}\theta}}}}$wherein

-   -   p_(z)=normal displacement of a selected surface location of said        contacting end of said indenter above a flat reference plane;    -   v=Poisson's Ratio of the material comprising said structure;    -   E=Elastic Modulus of the material comprising said structure;    -   P_(m)=a pre-selected uniform pressure greater than the yield        stress of the material comprising said structure;    -   a=radius of the contacting end of said indenter; and    -   θ, r=polar coordinates of a selected surface location on said        contacting end of said indenter.

Regardless, this method is characterized by working a bounding portionof material in a structure, where the bounding portion is adjacent apre-selected location for an opening in said structure, in order toprovide residual compressive stresses in said bounding portion forimproving the fatigue life of said structure. The method includesproviding a first compound indenter having a first indenter surfaceportion, where the first indenter surface portion adapted to impact thestructure at pre-selected surface locations adjacent said pre-selectedlocation for the desired opening in the structure. A second indentersurface portion is provided, adapted to impact the structure atpre-selected surface locations adjacent the pre-selected location forthe desired opening in said structure. The structure is indented by theprimary and secondary indenters for a selected dimple depth. Thisprovides beneficial residual stress in the structure toward the boundingportion of material of the structure.

Turning now to FIG. 11, the use of a pair of adjustable compoundindenters 120 and 122 as taught herein is depicted during automated workflow for indenting the obverse side 124 of a workpiece 126 located on aplaten or anvil 128. The adjustable compound indenters 120 and 124 canbe actuated downward in the direction of reference arrow 130 against theworkpiece 126 to provide suitable indentations 132 and 134 therein so asto provide a desired residual compressive stress pattern in theworkpiece 126 along sidewalls of apertures (not shown in FIG. 11) afterthe manufacture of the desired holes through the workpiece 126.Importantly, the compound indenters 120 and 122 can be moved asindicated by reference arrows 136 to impact on, and release from, theobverse surface 124 of workpiece 126 by using an appropriate strikingmechanism 138, which may be hydraulic, pneumatic, mechanical,electromechanical, electromagnetic, or any other appropriate strikingmechanism. Alternately, or additionally, one or more indenters 120 and122 affixed to mount 140 can be moved back and forth to and away fromworkpiece 126 by a ram or press actuator 142 or other suitable device asbetter indicated in FIG. 12.

FIG. 12 shows the use of a two pairs of adjustable compound indenters astaught herein to indent (a) the obverse side 126 of a workpiece usingindenters 120 and 122, as just described in reference to FIG. 11, sothat the adjustable compound indenters 120 and 122 can be actuateddownward against workpiece 126, and (b) the reverse side 150 ofworkpiece 126, so that the second pair adjustable compound indenters 160and 162 can be actuated upward against the reverse side 150 of workpiece126. Lower unit striking mechanisms 138L and work as described above forupper striking mechanisms 138. Lower mount 140L and lower press ram 142Lfunction as described above for the mount 140 and the press ram 142,respectively. Also, for automated manufacturing, it is anticipated thatsuch an apparatus will often include a base 170 and a stand 172, oftenincluding a generally C-shaped yoke 174, all as necessary for spacingupper compound indenters 120 and 122 and/or lower compound indenters 160and 162 at a desired distance from obverse 124 and reverse 150 sides ofa workpiece 126.

Each one of the adjustable compound indenters 120, 122, 160 and 162 canbe adjusted as required, both with respect to the length of primaryindenters (further described below) and with respect to the amount ofindentation (dimple depth “dd”) achieved in the workpiece 126, so as toprovide a desired residual compressive stress pattern in the workpiece126 after manufacture of desired holes through the workpiece 126.

Specific details of one embodiment for a desirable adjustable compoundindenter 120 are illustrated in FIG. 13. An adjustable primary indenter200 is adjustably secured in a primary indenter housing 202. Theindenter housing is removeably secured from an adapter block 204. A nosecap 210 is provided at the distal end of the indenter housing, with apassageway 212 therethrough defined by sidewalls 214 that is sized andshaped for passage of the support 216 of working end 218 of adjustableprimary indenter 200. A top plate 220 above sidewalls 222 of the adapterblock 204 provide a suitable location for a threaded adapter 224. Asbetter seen in FIG. 14, the primary adapter housing 202 utilizesexternal threads 230 for threaded engagement to the internal threads 232in the adapter block 204. More importantly, the primary indenter 200utilizes load receiving threads 240 for acting with respect to interiorthreads 242 in the indenter housing 202, for translating rotation of theprimary indenter into vertical motion, to change the primary indenter200 protruding length X between a first length X₁ and a second lengthX₂, with respect to the foot face portion 246 of nose cap 210.

The primary indenter 200 further includes a driver receiver 250 forreceiving the drive end 252 of a drive pin 254. The drive pen 254 isdrive pin is driven via a 90 degree worm type gear 258 or other suitablespeed reducer for connection to a stepper motor 260 (not shown, but seeFIG. 11 or FIG. 12) or other suitable drive for adjustment of the lengthX of the primary indenter 200. I have found that the necessary drivemechanism 258 is easily accomplished by use of speed reducer drivecatalogue number 2Z18-E0200, from Stock Drive Products, Inc. of 2101Jericho Turnpike, Box 5416, New Hyde Park, N.Y. 11042-5416. This deviceprovides input to rotating shaft 262 that is acted upon by theaforementioned stepper motor for turning as indicated by reference arrow264.

In FIG. 14, a vertical cross sectional view of the adjustable compoundindenter 120 just illustrated in FIG. 13, shown, additionally and moreclearly showing certain internal components, including drive pin 250 andthe 90 degree angle speed reducer 258 for connection to a stepper orother drive motor 260 suitable drive for turning the primary indenter200 to rotate in threads 242 of the primary indenter housing 202 toachieve vertical adjustment of the length X of the primary indenter 200.Also, note further details of the nose cap 210 with integral secondaryindenter 300 (better seen in FIG. 18 below) which is attached to thedistal end 302 of the primary indenter housing 202. Also illustrated isthe working end 218 primary indenter 200 that has indented a dimple 308in a workpiece 310 to a dimple depth of “dd”. It has been observed thatfor like materials and for like treatment, the dimple depths requiredare consistent. Thus, this provides for the use of dimple depths as aquality control measure for the process, and thus as a measure ofeffectiveness of the method.

FIG. 15 is an exploded perspective view of the adjustable compoundindenter 120 illustrated in FIGS. 13 and 14, now additionally showingcertain internal components, including threads 320 on threaded adapter224 for attachment to the threaded receiver 322 in top plate 220, andexternal threads 330 on the primary indenter housing 202 for receivinginternal threads 332 (see FIG. 14) in the nose cap 210, for threadedattachment of the nose cap 210 to the to the primary indenter housing202. Also shown is the knurled surface 340 of nose cap 210, suitable formanually affixing nose cap 210 to the primary indenter housing 202.Additionally, not the passageway defined by edgewall 342 for tightlyreceiving therethrough the support shaft 216 of the primary indenter200.

For a complete understanding of the invention, attention is directed toFIGS. 16, 17, and 18, each of which shows important details of the nosepiece or nose cap 210. In FIG. 16, a bottom view of the nose cap 210 isprovided, taken looking up at the nose cap 210 shown in FIG. 17. Asillustrated, the nose cap 210 includes an integral secondary indenter300, which is substantially in the form of a flat, annular contactingring. As shown, the secondary indenter 300 is of narrow radial width ofapproximately 0.003 inches (0.076 mm). Radially outward from thesecondary indenter 300, the contour of the nose piece 210 includes acontour 360 having a first blend angle bend of approximately 135° with a0.01 inch (0.25 mm) radius. Then, the contour of the nose piece 210includes a tertiary indenter 400 having an outside radius of 0.029inches (0.74 mm). Next, the contour of the nose cap 210 includes asecond blend radius 402, radially outward from the tertiary indenter400, having a second blend angle bend of approximately 133° with a 0.01inch (0.25 mm) radius. Next, the nose cap 210 includes a concave portion410 before flat portion 246 of foot 412 is completed. Importantly, thenose piece 210 has a contour, in the radially outward direction, whichincludes a foot 412 having an concave annular portion 410 radiallyoutward from a last, here second 402, blend radius. As illustrated, forwork on aluminum for many common fastener sizes, it has been found thatbest results are achieved by locating the concavity 402 at a locationapproximately 0.05 inches (1.27 mm) radially outward from the edge wall422 of a cylindrical slot for receiving said primary indenter, and todefine the concavity by removing material with an angle of approximatelyfive (5) degrees with respect to the flat surface 246 of foot 412. Formost applications, it is appropriate that the flat portion 246 of foot412 be oriented transverse to the axis of indentation (see referencenumeral 430 in FIG. 14) in workpiece 310.

Details of the primary indenter 200 as set forth in FIG. 19 have beenpreviously discussed. However, this figure more clearly shows drivereceiver 250 of depth of about 0.75 inches (19.05 mm) for receiving thedrive end 252 of drive pin 254. Also shown in better detail is theperipheral wall angle beta (β) of about five degrees, more or less,which enables cleaner indentation to and withdrawal from a workpiece.

Importantly, the supporting shaft 216 and end 218 of the primaryindenter 200, as well as the various components just described on thenose cap 210, are provided with a durable low friction coating. Thus,both the primary indenters, the secondary indenter, and any tertiaryindenters, ideally include such a durable low friction coating. Asuitable durable low friction coating includes a coating of chromiumnitride. Better yet, such a coating also includes tungsten disulfide.Such coatings, although relatively thin, have a thickness from 0.0002inches (0.005 mm) to about 0.0003 inches (0.008 mm). These low frictioncoatings reduces friction and shearing at the edge of the dimple, andallows better radial flow of metal, which in turn provides greaterresidual stress, thus better achieving the ultimate objective, greaterfatigue life improvement. Also, such coatings also reduce strippingforce as the primary 200 and secondary 300 indenters are removed, aswell as minimize metal pickup on the indenter surface.

The use of the compound indenters in manufacturing of thick stacks ofmaterial is further shown by FIGS. 20, 21, 22, 23, and 24. FIG. 20illustrates the use of opposing, integral, one-piece compound indenterson a thick stack, to create desirable residual stresses in both thefirst side of an upper workpiece and in the second side of a lowerworkpiece, so that desirable compressive stress is created throughoutthe thick stack. With respect to FIGS. 20 and 21, it should be notedthat the anticipated actual aperture hole edge location 480 may belocated radially inward of, or radially outward of, the peripheral edge502 of the indenter 503 or peripheral edge 504 of indenter 506. Thechoice of wall location is dependent on various factors, mostimportantly of course the amount of beneficial residual stress present,after treatment, at the pre-selected wall location.

Another feature of the method of the present invention is the use of wetsealant, or bonding agent between a first and second workpiece, suchsealant 920 between workpiece 900 and 910 illustrated in FIG. 21. Thisis important in the manufacture of aircraft for corrosion resistance andwet wing construction using polysulfide type sealants or othermaterials.

FIG. 22 illustrates the use of a flush rivet with a shank portion tojoin a first workpiece having a chamfered hole edge therein toaccommodate the flush rivet head, and a second workpiece having astraight or transverse hole edgewall therethrough for accommodating theshank of the rivet. FIG. 23 illustrates the use of rivet having a roundhead to join a first workpiece having a straight or transverse holeedgewall therethrough, and a second workpiece also having a straight ortransverse hole edgewall therethrough. In FIG. 22, the peripheral edge802 of a fastener 800, is shown with a small indentation IF adjacentthereto. FIG. 22 is particularly interesting since it provides anindication that a countersunk type outer edge wall 804 can be preparedaccording to the methods described herein to provide a desirablebeneficial residual stress pattern in the body 806 of structure 808.Likewise, the body 810 of structure 812 adjacent to the moreconventional perpendicular edge wall 814 can be treated to provide adesirable beneficial stress pattern in the body 810. Moreconventionally, as shown in FIG. 23, a fastener 840 having an externallyprotruding head 842 is provided to join structural members 844 and 846.In such structures, apertures defined by sidewalls 848 and 850,respectively, accommodate the fastener shank 852. The beneficialresidual stress is advantageously provided in both structural member 844and in member 846.

Although it is generally expected that most structures wouldsubstantially benefit from increased fatigue resistance being impartedfrom both the obverse and the reverse sides of the structure. However,in some applications, there may arise useful results when only a singleside is treated. Such one-sided treatment of a structure is depicted inFIG. 21. Here, a first workpiece 900 has been dimpled 902 in a single,obverse side 904 according to the method taught herein. Preferably, atapered drill 906 is utilized to drill the desired aperture, throughworkpiece 900, as well as through matching workpiece 910 in which nocold working for stress relieve has been achieved. Alternately, in FIG.20, single side working of two workpieces in a stack is depicted.Indenters 503 and 506 are used to provide beneficial residual stressnear the desired locations for fastener apertures in the finishedstructure fabricated from the workpiece 532 and 534.

FIG. 24 illustrate the use of a tapered drill 906 for drilling a blindhold defined by edgewall 940 in thick workpiece 942.

Further, it is also important to understand that unusual configuration,non-circular type apertures can be treated with the method describedherein, to provide beneficial residual stress levels at desiredlocations bounding locations adjacent the interior edge wall of throughpassageways in structures. Thus, structures having non-circular holestherein can advantageously be treated with this method to providebeneficial residual stress levels at desired locations in the structure.

It is to be appreciated that the novel compound indenter, and theprocess of utilizing such compound indenter in thick materials or deepstack workpieces, to reduce fatigue stress degradation of such parts, isan appreciable improvement in the state of the art of cold working metalparts subject to fatigue concerns. Importantly, this compound indenterand the method of employing the same can advantageously treat a holebefore it is machined. Thus, the tooling apparatus and the method of itsuse disclosed herein provide substantial improvement over currently usedtreatment methods by eliminating various tooling and tooling aids, suchas expansion mandrels, sleeves, and hole lubricants.

In this improved method, control of the magnitude and depth of residualstress is determined by the properties and characteristics of aparticular workpiece, nature of the force or displacement imparted onthe workpiece, as particularly and effectively accomplished viaadvantageous use of appropriately dimensioned and designed compoundindenters. Importantly, the use of a compound indenter in manufacturingprocess as disclosed herein are readily automated and can be put intoany automated fastening environment. Although only a few exemplaryembodiments of this invention have been described in detail, it will bereadily apparent to those skilled in the art that our novel methods forcold working metal, and the tooling and other apparatus foradvantageously implementing such processes, may be modified from thoseembodiments provided herein, without materially departing from the novelteachings and advantages provided herein, and may be embodied in otherspecific forms without departing from the spirit or essentialcharacteristics thereof. Therefore, the embodiments presented herein areto be considered in all respects as illustrative and not restrictive. Assuch, the disclosure and the claims are intended to cover the structuresdescribed herein and not only structural equivalents thereof, but alsoequivalent structures. Thus, the scope of the invention is intended toinclude all variations described herein, whether in the specification orin the drawing, including the broad meaning and range properly affordedto the language and description set forth herein to describe suchvariations. Therefore, it will be understood that the foregoingdescription of representative embodiments of the invention have beenpresented only for purposes of illustration and for providing anunderstanding of the invention, and it is not intended to be exhaustiveor restrictive, or to limit the invention only to the precise formsdisclosed. Alternative features serving the same or similar purpose mayreplace each feature disclosed in this specification (including anyaccompanying claims, the various figures of the drawing), unlessexpressly stated otherwise. Thus, each feature disclosed is only oneexample of a generic series of equivalent or similar features. Further,while certain materials are described for the purpose of enabling thereader to make and use certain embodiments shown, such suggestions shallnot serve in any way to limit the claims to the materials disclosed, andit is to be understood that other materials, including other metals andvarious compositions, may be utilized in the practice of our methods,and in the manufacture of structures utilizing the apparatus and methodsdisclosed herein.

The intention is to cover all modifications, equivalents, andalternatives falling within the scope and spirit of the invention, asexpressed herein above and in the appended claims. As such, the claimsare intended to cover the structures, apparatus, and methods describedherein, and not only the equivalents or structural equivalents thereof,but also equivalent structures or methods. The scope of the invention,as described herein and as indicated by the appended claims, is thusintended to include variations from the embodiments provided which arenevertheless described by the broad meaning and range properly affordedto the language of the claims, as explained by and in light of the termsincluded herein, or the equivalents thereof.

1. A method for working a bounding portion of material in a structure,said bounding portion adjacent a pre-selected location for an opening insaid structure, in order to provide residual compressive stresses insaid bounding portion for improving the fatigue life of said structure,said method comprising: providing a first compound indenter, said firstcompound indenter comprising a first indenter surface portion, saidfirst indenter surface portion adapted to impact said structure atpre-selected surface locations adjacent said pre-selected location forsaid opening in said structure, and a second indenter surface portion,said second indenter surface portion adapted to impact said structure atpre-selected surface locations adjacent said pre-selected location forsaid opening in said structure; indenting said pre-selected surfacelocation of said structure with said first compound indenter to provideresidual stress in said structure toward said bounding portion ofmaterial.
 2. The method as set forth in claim 1, further comprisingremoval of a selected portion of material from said structure, saidselected portion of material removed from said structure having an outerborder portion, said outer border portion located at or adjacent to saidpre-selected surface location on said structure having been impacted bysaid first shaped surface portion and said second shaped surface portionof said first compound indenter, so that said bounding portion ofmaterial expands transversely to said outer border portion of saidselected portion of material removed from said structure.
 3. A methodfor working a bounding portion of material in a structure, said boundingportion adjacent a pre-selected location for an opening in saidstructure, in order to provide residual compressive stresses in saidbounding portion for improving the fatigue life of said structure, saidmethod comprising: providing a first compound indenter, said firstcompound indenter comprising a first indenter surface portion, saidfirst indenter surface portion adapted to deform said structure atpre-selected surface locations adjacent said pre-selected location forsaid opening in said structure, and a second indenter surface portion,said second indenter surface portion adapted to deform said structure atpre-selected surface locations adjacent said pre-selected location forsaid opening in said structure; deforming said pre-selected surfacelocation of said structure with said first compound indenter to provideresidual stress in said structure toward said bounding portion ofmaterial.
 4. The method as set forth in claim 3, further comprisingremoval of a selected portion of material from said structure, saidselected portion of material removed from said structure having an outerborder portion, said outer border portion located at or adjacent to saidpre-selected surface location on said structure having been deformed bysaid first shaped surface portion and said second shaped surface portionof said first compound indenter, so that said bounding portion ofmaterial expands transversely to said outer border portion of saidselected portion of material removed from said structure.
 5. The methodas set forth in claim 1 or claim 3, wherein said first compound indentercomprises a dynamic indenter.
 6. The method as set forth in claim 2 orclaim 4, wherein removal of said selected portion of material from saidstructure defines an elongated recessed portion.
 7. The method as setforth in claim 6, wherein said elongated recessed portion comprises aclosed end portion.
 8. The method as set forth in claim 2 or claim 4,wherein removal of said selected portion of material from said structuredefines a through passageway.
 9. A method of manufacturing a joint whichincludes overlapping at least first and second structural members, saidmethod comprising: (a) contacting a preselected portion of said firststructural member with a first compound indenter at a pressure greaterthan the yield point of the composition of said structural member todeform a portion of said first structural member in a manner so as toimpart a pre-selected residual stress at a location at or near aselected location for a first fastener aperture through said firststructural member, and wherein said residual compressive force issubstantially uniform along the entire length of sidewall portions ofsaid first fastener aperture; (b) machining said first structural memberto define said first fastener aperture via sidewall portions resultingfrom said machining; (c) providing in said second structural member, asecond fastener aperture defined by second sidewall portion; (d)inserting a fastener through said first and said second fastenerapertures; (e) securing said fastener.
 10. The method of claim 9,further comprising the step of applying force or displacement to saidfastener to seat said fastener within said first and said secondfastener apertures.
 11. The method of claim 10, wherein the step ofseating said fastener further comprises deforming an end portion of saidfastener in order to secure and retain said fastener against said firststructural member.
 12. The method as set forth in claim 9, wherein thedepth of indentation on the obverse and the reverse sides is different.13. The method as set forth in claim 9, further comprising, postindentation, the step of drilling a hole into or through said workpiece.14. The method as set forth in claim 13, wherein said step of drillingcomprises a drilling step selected to provide a finished hole selectedfrom the group consisting of (a) straight through hole, (b) steppedhole, (c) a blind hole, (d) a countersink hole, (e) a non-round ornon-circular hole.
 15. The method as set forth in claim 14, furthercomprising the step of threading the hole.
 16. The method as set forthin claim 9, further comprising (a) contacting a preselected portion ofsaid second structural member with a first compound indenter at apressure greater than the yield point of the composition of said secondstructural member to deform a portion of said second structural memberin a manner so as to impart a pre-selected residual stress at a locationat or near a selected location for said second fastener aperture throughsaid second structural member, and wherein said residual compressiveforce is substantially uniform along the entire length of sidewallportions of said second fastener aperture.
 17. A method formanufacturing a workpiece for having an enhanced fatigue life structure,said workpiece of the type having a first surface, a second surface, athickness of material therebetween, and at least a first preselectedlocation at which a hole having an edge location is to be fabricated insaid workpiece, said method comprising: (a) securing said workpiece at afirst working location, said first working location suitable for pressforming work on said workpiece; (b) deforming a preselected location onsaid workpiece by indenting said workpiece at said preselected locationwith a compound indenter, to create residual compressive stressesthrough said thickness of said material of said workpiece along saiddesired hole edge location (c) machining an aperture in said workpieceto provide said hole in said workpiece.
 18. The method of claim 17,wherein the deformation of said workpiece results in a predeterminedzero hoop stress profile, after reaming, substantially as set forth inFIG.
 10. 19. The method of claim 17, wherein the deformation of saidworkpiece results in a residual compressive stress along said hole edgelocation through said material thickness of said workpiece, from saidfirst side of said workpiece to said second side of said workpiece. 20.The method of claim 17, further comprising the steps of: (a) determiningdesired application of stress and strain in said workpiece during saidindentation step, by using finite-element analysis of the workpiece andthe relationship of residual stress as a function of the material of theworkpiece as well as of the applied force and indenter shape; (b)selecting an appropriate indenter shape and applied force to form theworkpiece while avoiding surface upset on the workpiece.
 21. The methodas set forth in claim 1, or in claim 3, or in claim 9, or in claim 17,wherein said first compound indenter further comprises a first footportion.
 22. The method as set forth in claim 21, wherein said firstfoot portion applies a load to said workpiece sufficient tosubstantially avoid surface upset in said workpiece.
 23. The method asset forth in claim 22, wherein said load applied to said workpiece isapplied prior to impacting or deforming said workpiece.
 24. The methodof claim 17, wherein said method of manufacturing involves advancingsaid workpiece in incremental steps in a machine to position saidworkpiece to the repetitive action of one or more selected compoundindenters, to thereby create desirable residual compressive stress at aplurality of preselected locations, and (b) machining an aperture at aplurality of said preselected locations, so as to provide a plurality ofholes in said workpiece each having improved fatigue life by virtue ofhaving residual compressive stress along at least a portion of an edgewall of said hole.
 25. The method as set forth in claim 24, wherein saidresidual compressive stress is provided along the entire hole edge wallthroughout the thickness of said workpiece between said first surfaceand said second surface.
 26. A method for making a thick metal part inwhich holes are to be fabricated at predetermined locations, said parthaving first and second surfaces and a thickness of materialtherebetween, said method comprising the steps of: (a) providing a thickmetal plate (b) applying a controlled strain and/or stress rate at atleast one of said predetermined locations at which holes are to beformed, by indenting said part with a compound indenter, said indenterof the type having a primary indenter, a secondary indenter, a tertiaryindenter, and a foot, by actuating a ram against said first surface ofsaid part; and (c) machining the indented part to remove material toshape a hole and thus convert the thick metal plate into a finishedpart. (d) wherein the manufacture forming greatly reduces the handlingnecessary by allowing said hole to be fabricated by a single drillingoperation to provide a hole in a desired configuration in the finishedpart.
 27. The method of claim 26, wherein forming occurs with the zerohoop stress relationship as a function of dimple depth substantially asset forth in FIG.
 10. 28. The method as set forth in claim 26, whereinsaid foot applies a load to said workpiece sufficient to substantiallyavoid surface upset in said workpiece.
 29. A joint comprising: (a) astack of structural members including (1) a first member having a bodymade of material in which a first fastener aperture defined by a firstedge wall portion is conditioned by the method of claim 1, or of claim3, or of claim 9, or of claim 17, or of claim 26 to have a residual,radially inward compressive stress, and (2) a second member having asecond fastener aperture defined by a second edge wall portion, saidsecond fastener aperture aligned with said first fastener aperture; (b)an interference fit fastener including a shank portion, said shankportion located adjacent said first fastener aperture and adjacent saidsecond fastener aperture, and wherein said first fastener apertureprovides residual compressive stresses around said shank.
 30. The jointas set forth in claim 29, wherein said second edge wall portion in saidsecond member is conditioned to have radially inward compressiveresidual stress.
 31. The joint as set forth in claim 29, wherein saidinterference fit fastener comprises a flush type rivet furthercomprising a countersunk portion, and wherein said residual compressivestress is applied through said body of said first member along saidcountersunk portion of said rivet.
 32. The joint as set forth in claim31, wherein said interference fit fastener comprises a rivet having astraight shank portion, and wherein said residual compressive stress isapplied substantially uniformly through said body of said first memberalong said first edge wall portion.
 33. A joint comprising: (a) a stackof structural members comprising (1) a first member having a body madeof material in which a first fastener aperture defined by a first edgewall portion is conditioned by the method of claim 1, or of claim 3, orof claim 9, or of claim 17, or of claim 26, to have a residual, radiallyinward compressive stress, and (2) a second member having a secondfastener aperture defined by a second edge wall portion, said secondfastener aperture aligned with said first fastener aperture; (b) one ormore fasteners, said one or more fasteners securely affixing said firstmember to said second member.
 34. The joint as set forth in claim 32,wherein said second edge wall portion in said second member isconditioned to have radially inward compressive residual stress.
 35. Thejoint as set forth in claim 29, or in claim 33, wherein said jointfurther comprises, between said first and said second members, a sealingcompound.
 36. The joint as set forth in claim 29, or in claim 33,wherein said joint further comprises, between said first and said secondmembers, a wet sealant, and wherein in said wet sealant is cured afterprocessing.
 37. The joint as set forth in claim 29, or in claim 33,wherein said joint further comprises, between said first and said secondmembers, a bonding compound.
 38. The joint as set forth in claim 29, orin claim 33, wherein said joint comprises two members.
 39. The joint asset forth in claim 29, or in claim 33, further comprising a thirdmember, and wherein said joint comprises at least three members.
 40. Ametal plate structure that is manufactured for enhanced fatigue life,said structure having a first surface, a second surface, a thickness ofmaterial therebetween, and at least a first preselected location atwhich a hole having an edge location is to be fabricated, said metalplate structure manufactured using a method comprising: (a) securingsaid metal plate structure at a first working location, said firstworking location suitable for press forming work on said metal platestructure; (b) deforming a preselected location on said metal platestructure by indenting said metal plate structure at said preselectedlocation with a compound indenter, to create residual compressivestresses through said thickness of said material of said metal platestructure along said desired hole edge location (c) machining anaperture in said metal plate structure to provide said hole in saidmetal plate structure.
 41. The metal plate structure as set forth inclaim 40, wherein said metal plate structure is manufactured by a methodwherein said deformation of said metal plate structure in apredetermined zero hoop stress profile, after reaming, substantially asset forth in FIG.
 10. 42. The metal plate structure as set forth inclaim 40, wherein said metal plate structure is manufactured by a methodwherein said deformation of said metal plate structure results in aresidual compressive stress along said hole edge location through saidmaterial thickness of said metal plate structure, from said first sideof said metal plate structure to said second side of said metal platestructure.
 43. An article of manufacture comprising a metal part, saidmetal part having predetermined locations in which holes are fabricated,said metal part having first and second surfaces and a thickness ofmaterial therebetween, said metal part manufactured according to amethod comprising the steps of: (a) providing a metal plate (b) applyinga controlled strain and/or stress rate at at least one of saidpredetermined locations at which holes are to be formed, by indentingsaid metal plate with a compound indenter, said indenter of the typehaving a primary indenter, a secondary indenter, a tertiary indenter,and a foot, by actuating a ram against said first surface of said metalplate; (c) machining the indented metal plate to remove material toshape a hole and thus convert the metal plate into a finished metalpart; (d) wherein said holes are fabricated by a single drillingoperation to provide a hole in a desired configuration in said finishedmetal part.
 44. The part of claim 43 wherein the workpiece comprisesaluminum.